Fiber-metal laminate and its manufacturing method

Abstract

A fiber-metal laminate, includes fiber cloth; a resin layer, disposed on the fiber cloth; a metal layer, disposed on the resin layer; and a plurality of chopped fibers, distributed between the fiber cloth and the resin layer; wherein each chopped fiber includes a first part inserted into the fiber cloth and a second part fixed in the resin layer. A method of manufacturing the fiber-metal laminate is also provided.

1 . A fiber-metal laminate, comprising:
 fiber cloth;   a resin layer, disposed on the fiber cloth;   a metal layer, disposed on the resin layer; and   a plurality of chopped fibers, distributed between the fiber cloth and the resin layer,   wherein each chopped fiber comprises a first part inserted into the fiber cloth and a second part fixed in the resin layer.   
     
     
         2 . The fiber-metal laminate of  claim 1 , wherein the chopped fiber is selected from a group consisting of glass fiber, carbon fiber, aramid fiber and combination thereof. 
     
     
         3 . The fiber-metal laminate of  claim 1 , wherein the chopped fiber has a length of 6 mm to 30 mm, and has a cross-sectional diameter of 10 μm to 30 μm. 
     
     
         4 . The fiber-metal laminate of  claim 1 , wherein the metal layer is one selected from a group consisting of aluminum alloy plate, titanium alloy plate, and steel plate; and the metal layer has a thickness of 0.1 mm to 2 mm. 
     
     
         5 . The fiber-metal laminate of  claim 1 , wherein a surface of the metal layer towards the resin layer is provided with a plurality of micropores having an average diameter of 15 μm to 50 μm. 
     
     
         6 . The fiber-metal laminate of  claim 5 , wherein the surface of the metal layer towards the resin layer is of an anodic oxide layer being in contact with the resin layer. 
     
     
         7 . The fiber-metal laminate of  claim 1 , wherein the fiber cloth is selected from a group consisting of glass fiber cloth, carbon fiber cloth, aramid fiber cloth, and combination thereof; and the fiber cloth has a thickness of 0.1 mm to 2 mm. 
     
     
         8 . The fiber-metal laminate of  claim 1 , wherein the resin layer is selected from a group consisting of acrylic resin layer, epoxy resin layer, urethane resin layer and combination thereof; and the resin layer has a thickness of 0.1 mm to 2 mm. 
     
     
         9 . The fiber-metal laminate of  claim 1 , wherein the metal layer comprises a first metal layer and a second metal layer, and the resin layer comprises a first resin layer and a second resin layer;
 wherein the second resin layer is disposed on the second metal layer;   the fiber cloth is disposed on the second resin layer;   the first resin layer is disposed on the fiber cloth;   the first metal layer is disposed on the first resin layer; and   the plurality of chopped fibers is distributed both between the second resin layer and the fiber cloth, and between the fiber cloth and the first resin layer.   
     
     
         10 . A method for manufacturing a fiber-metal laminate of  claim 1 , comprising steps of:
 providing a plurality of chopped fibers on a surface of the fiber cloth;   inserting a first part of the chopped fiber into the surface of the fiber cloth;   immersing the surface of the fiber cloth inserted with the first part of the chopped fiber into a resin slurry to obtain immersed fiber cloth;   overlaying a metal layer on the immersed fiber cloth; and   hot pressing to obtain the fiber-metal laminate.   
     
     
         11 . The method of  claim 10 , wherein the first part of the chopped fiber is inserted into the surface of the fiber cloth by needle-punching treatment. 
     
     
         12 . The method of  claim 11 , wherein the needle-punching treatment is performed at a needle density of 100 times/cm 2  to 250 times/cm 2 , and a needle depth of 0.1 mm to 0.5 mm. 
     
     
         13 - 14 . (canceled) 
     
     
         15 . The method of  claim 10 , wherein the step of providing the plurality of chopped fibers on the surface of the fiber cloth is performed by steps of:
 placing the fiber cloth in an ethanol solution;   adding the plurality of chopped fibers into the ethanol solution under an ultrasonic condition;   depositing the plurality of chopped fibers on the surface of the fiber cloth; and   drying the fiber cloth deposited with the plurality of chopped fibers.   
     
     
         16 . The method of  claim 15 , wherein 0.1 g to 1 g of the chopped fiber is added for each square centimeter of the fiber cloth. 
     
     
         17 . The method of  claim 10 , wherein the step of providing the plurality of chopped fibers on the surface of the fiber cloth comprises:
 providing the plurality of chopped fibers on a first surface of the fiber cloth; and   providing the plurality of chopped fibers on a second surface of the fiber cloth.   
     
     
         18 . The method of  claim 17 , wherein the method comprises steps of:
 immersing the first and second surfaces of the fiber cloth inserted with the first part of the chopped fiber into the resin slurry;   overlaying a first metal layer on the first surface of the fiber cloth, and a second metal layer on the second surface of the fiber cloth; and   hot pressing to obtain the fiber-metal laminate.   
     
     
         19 . The method of  claim 10 , wherein the surface of the fiber cloth inserted with the first part of the chopped fiber is immersed into the resin slurry for 10 minutes to 60 minutes, to form a resin slurry layer with a thickness of 0.1 mm to 2 mm on the surface of the fiber cloth. 
     
     
         20 - 21 . (canceled) 
     
     
         22 . The method of  claim 10  further comprising steps of:
 forming a plurality of micropores having an average diameter of 15 μm to 50 μm at a surface of the metal layer, and 
 attaching the surface of the metal layer formed with the plurality of micropores with the surface of the immersed fiber cloth inserted with the first part of the chopped fiber. 
 
     
     
         23 . The method of  claim 22 , wherein the plurality of micropores is formed by a chemical etching method, a laser pore-forming method, an arc pore-forming method, or an electrochemical oxidation method. 
     
     
         24 . The method of  claim 10 , wherein the step of hot pressing is performed at a temperature of 140° C. to 200° C. and a pressure of 0.1 MPa to 20 MPa for 10 minutes to 30 minutes.